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Microsoft Corp. is working with the OPC Foundation to enable almost any IIoT scenario using interoperability between the millions of OPC UA-compliant applications and equipment. Microsoft will enable IIoT users to connect manufacturing equipment and software with extended support of OPC UA's open-source software stack. Microsoft’s extended support for OPC UA spans its IoT offerings from local connectivity with Windows devices to cloud connectivity via Microsoft Azure. Integration with Azure IoT allows customers to easily send OPC UA data to the Azure cloud, as well as command and control OPC UA devices remotely from the Azure cloud.
Pepperl+Fuchs broke ground June 2 on its new U.S. distribution and engineering center in Katy, Texas, near…

While routine build-up and clogging in process applications is annoying, process scaling is more persistent, causes unplanned downtime and increases costs in many industries. It's typically composed of calcium carbonate, wax, grease or similar…

Just as you can't have too many friends, level measurement applications can't get enough ease of use, reliability and safety. Thanks to increasing process industry needs and user demand for them, these are the three unifying priorities that drove…

Our panel of experts explore best practices for dealing with buildup on chemical seals of a differential pressure flowmeter.

Q: We have a venturi flowmeter with 3-in. flanged pressure taps and flanged chemical seals with capillary tubes in a 44-in. vertical pipe (Figure 1). The fluid is hydrocarbon (polymeric) gas. The problem is that the chemical seal diaphragms often…

A Control Design reader writes: We have several temperature, pressure and flow sensors on a new medical-device cleaning skid that we are developing. These instruments are connected to a PLC as 4-20 mA inputs, and there is also a 4-20 mA output used to control a pump motor speed. A recent failure of a flow sensor brought the process skid instrumentation to my company's quality manager's attention. He asked how we know that the temperatures, pressure and flow are accurate, and how do we know that we are cleaning properly.
I've been tasked to write a procedure for troubleshooting, calibrating and testing the 4-20 mA instruments on the skid. I can probably stumble through this, but what are some best practices for troubleshooting the analog…

Control's Monthly Resource Guide brings you the latest online resources on a variety of process control topics.

MULTI-PART WEIGHING
This four-section webpage by Omega Engineering covers "Weighing Applications," "Weighing System Design," "Installation and Calibration" and "Specialized Installations." The whole group is located at…

FOPDT model has demonstrated utility for controller tuning rules, for structuring decouplers and feedforward control algorithms.

A first-order plus deadtime (FOPDT) model is a simple approximation of the dynamic response (the transient or time-response) of a process variable to an influence. It’s also called first-order lag plus deadtime (FOLPDT), or “deadtime” may be…

'To the degree networks and standards can provide easy, consistent and seamless access to device-resident controls, the vision of truly distributed control may finally dawn upon us.'

Every compressor in the facility went down at once that day, when a PLC redundancy switchover didn’t transfer in time. The engineers didn’t know that each P453 remote I/O processor had a dip-switch-selectable timeout setting—if it didn’t…

A Control Design reader writes: We have several temperature, pressure and flow sensors on a new medical-device cleaning skid that we are developing. These instruments are connected to a PLC as 4-20 mA inputs, and there is also a 4-20 mA output used to control a pump motor speed. A recent failure of a flow sensor brought the process skid instrumentation to my company's quality manager's attention. He asked how we know that the temperatures, pressure and flow are accurate, and how do we know that we are cleaning properly.
I've been tasked to write a procedure for troubleshooting, calibrating and testing the 4-20 mA instruments on the skid. I can probably stumble through this, but what are some best practices for troubleshooting the analog…

Most public utilities deliver basic power and water, and God bless them for doing it. However, a few go beyond their essential missions, and seek to further enhance the overall well-being and prosperity of their communities.
One of these is…

Advanced control on fuel and steam can control emissions while saving millions.

It’s no secret that advanced process control (APC) has played a major role in the process industries for many decades. However, while many organizations focus only on major process units, there’s often an untapped opportunity to do more, and…

Our readers tell us who they think delivers the best technology in our industry

There's knowledge in our readers. That's why every year we ask our loyal audience to help us determine which automation service providers offer the best products and brands they can rely on to get the best combination of performance, ease of use,…

Just when it seems like today’s sophisticated motors and drives can’t possibly add more efficiencies and capabilities, engineers conjure up new tricks and refinements, followed by end users and system integrators who materialize new settings and…

Control's monthly guide brings you invaluable industry information to stay up to date on the latest trends and developments.

THE CLASSIC VALVE BOOK
The fourth edition of the 295-page classic text, "Control Valve Handbook," by Fisher Controls International and Emerson Process Management reports this classic text has been a primary reference since its first printing in1965.

Control's monthly guide brings you invaluable industry information to stay up to date on the latest trends and developments.

THE CLASSIC VALVE BOOK
The fourth edition of the 295-page classic text, "Control Valve Handbook," by Fisher Controls International and Emerson Process Management reports this classic text has been a primary reference since its first printing in1965.

Just when it seems like today’s sophisticated motors and drives can’t possibly add more efficiencies and capabilities, engineers conjure up new tricks and refinements, followed by end users and system integrators who materialize new settings and…

Actionable information is essential for the effectiveness of the 'loop,' as it is for closed-loop control and open-loop alarms.

When I sat down in my office this morning, I was greeted by the operations manager, who pointed out an entry from last night’s operations log: “Did you see? The boiler steam vent is in manual because the pressure reading whacked out and made the…

Actionable information is essential for the effectiveness of the 'loop,' as it is for closed-loop control and open-loop alarms.

When I sat down in my office this morning, I was greeted by the operations manager, who pointed out an entry from last night’s operations log: “Did you see? The boiler steam vent is in manual because the pressure reading whacked out and made the…

Actionable information is essential for the effectiveness of the 'loop,' as it is for closed-loop control and open-loop alarms.

When I sat down in my office this morning, I was greeted by the operations manager, who pointed out an entry from last night’s operations log: “Did you see? The boiler steam vent is in manual because the pressure reading whacked out and made the…

Our readers tell us who they think delivers the best technology in our industry

There's knowledge in our readers. That's why every year we ask our loyal audience to help us determine which automation service providers offer the best products and brands they can rely on to get the best combination of performance, ease of use,…

Visualizing and contextualizing safety data can have a positive impact on productivity and compliance.

"Information is one thing, but safety information is quite another," says George Schuster. He should know. He’s charged with business development for the Global Safety Team of Rockwell Automation and has seen many plants and factories begin to…

How to deal with the constraints of putting access points in hazardous areas.

In an ideal world, it wouldn’t be necessary to worry about explosive atmospheres. Unfortunately, plant environments are far from ideal, with most process plants being about 80% Class I, Div. 2 (Zone 2) and another 10% Class I Div. 1 (Zone 1), so…

Key is to learn as much as possible to make digital technologies safe, secure and successful in process settings.

As usual, and I’m sure this is true for many of you, this year’s autumn season has been a frantic dash of work, deadlines, sleep deprivation, indigestion and suspiciously arthritic stiffness. In my case, this means covering all sides of the…

With today’s network technology, even Ethernet and wireless are almost always fast enough.

As automation professionals, one issue we have about control loops is ensuring we're able to support real-time control. Historically, when Ethernet was 10 MB/s and there were multiple drops on a single port, collisions were a significant concern and…

With today’s network technology, even Ethernet and wireless are almost always fast enough.

As automation professionals, one issue we have about control loops is ensuring we're able to support real-time control. Historically, when Ethernet was 10 MB/s and there were multiple drops on a single port, collisions were a significant concern and…

Because they're the crossroads, nexus and Grand Central Station for sensor signals and data arriving and requests and actuation instructions departing, it's a big help that I/O and terminal blocks are more flexible and capable than ever.

Compact, Remote I/O for Zone 2/Div 2
LB System remote I/O has more power in less space with high-performance, compact modules plugged into a backplane. Energy-saving power management and low-power dissipation allow maximum packing density. With the…

Be just 33 seconds more productive each hour, and the savings mount quickly.

Rockwell Automation previewed its new, forward-looking App Platform for mobility at this week’s TechED conference in Orlando. While focused first on redefining smartphone use on the plant floor – with the aim of making individual workers more…

Control’s latest State of Technology report delves into the many aspects of power systems of interest in process plants.

From sourcing and ensuring uninterrupted flows of clean electricity to monitoring, regulating and metering generation and consumption throughout a facility, process automation professionals who want a smooth-running, efficient and reliable facility are well advised to seek and control power.
This anthology of recent articles delves into the many aspects of power systems of interest in process plants. Remote and wireless systems are speeding development and standardization of energy harvesting and improved battery systems.
Line-powered supplies that used to only transform electricity and maybe offer surge protection are now monitoring and measuring current and voltage profiles, implementing alerts and alarms, and sending data up to…

Greg: Here we take advantage of the chance to talk to Bill Thomas, who provides a great lesson of how to succeed in advancing capabilities and opportunities in his career and the control systems for which he was responsible. His career and the…

Control's monthly guide brings you invaluable industry information to stay up to date on the latest trends and developments.

AT THEIR BEST, ALL THE TIME
ExperTune’s white paper, “How to Improve Performance of Process Control Assets,” by George Buckbee, P.E., describes the practice of real-time asset performance management, shows how to get assets to perform at their best all the time, and demonstrates the value of integrating these tools for a performance picture that delivers financial results. It’s available here.
ISA / www.isa.org
ANALYZING, PREDICTING PROBLEMS
This 57-minute video, “Avoid Equipment Surprises: Predictive Diagnostics for Oil & Gas,” is presented by Joe Dupree, GE Automation and Controls, and users from NiSource Gas and Alyeska. They demonstrate condition-based monitoring, predictive analytics and other tools for evaluating…

Steve Christian remembers the days—not too long ago—when production schedules were printed on sheets of paper and distributed to operators at his plant, who would manually twist valve handles to send the Ragu sauce tomato slurry from one kettle…

Advanced control on fuel and steam can control emissions while saving millions.

It’s no secret that advanced process control (APC) has played a major role in the process industries for many decades. However, while many organizations focus only on major process units, there’s often an untapped opportunity to do more, and…

Find and slay the dragons lurking in the typical safety instrumented system.

Cybersecurity is a growing concern in the process industries, and a number of good articles have been written about it for industrial control systems (ICS)—many full of doom and gloom. Here, we will divide the ICS into two parts: safety…

Big data can only help users if they understand what it is, how it can affect their controls and processes, and how they can use it to optimize operations.

Similar to any new technology emerging on the process control front, big data can only help users make better decisions if they understand what it is, how it can affect their controls and processes, and how they can use it to optimize operations.

Our readers tell us who they think delivers the best technology in our industry

There's knowledge in our readers. That's why every year we ask our loyal audience to help us determine which automation service providers offer the best products and brands they can rely on to get the best combination of performance, ease of use,…

Read Andrew Bonds Industrial Automation Insider, a monthly newsletter covering the important industrial automation news and issues as seen from the U.K.

The study has also found that ProfiNet’s data delivery via individual frames benefits more from increasing bit rates of, for example, 1000 Mbps than other transmission methods. Moreover, for larger amounts of user data in the branching topologies used in more complex systems, the transmission method used by ProfiNet IRT always yields performance advantages compared with protocols using summation frame techniques.

Phoenix contact and its partners plan to demonstrate prototype systems based on their findings at the Hanover Fair in April 2008.

Brazilian process automation vendor Smar reports rapid uptake of digital networks, especially of Profibus DP and PA, in the burgeoning Brazilian ethanol from sugar cane market which is predicted to be worth more than $15bn by 2012. Particular drivers are the need for low-cost technology for implementation, data protection, ease of operation and maintenance, and complete integration between field instrumentation and control system. According to Smar, more than 50% of new sugar and ethanol plants in Brazil are currently being designed with Profibus technology.

Typical of the new projects is that for Tropical Bioenergia which includes some 1000 Profibus nodes supervised by 15 Smar DFI302 DF73 controllers and overseen by Smar’s System302-7 decentralized architecture hybrid control system. Smar has also recently signed a contract with Santa Elisa Distillery, a subsidiary of major sugar ethanol producer Santelisa-Vale Group (SVG), for the complete automation of four new plants. In each case, Smar will supply its System302-7 control system together with complete Profibus- enabled field instrumentation, controllers and control panels. The project also involves provision of a Center of Integrated Operations (COI) based on a successful Smar system previously implemented for Santa Elisa. Smar will be supplying more than 3200 Profibus PA field instruments and four supervisory control systems. In addition AS-I technology will be used for the control of the on-off valves and sensors. Two of the four units are due to begin operation in July 2008 with the other two starting up in May 2009. A further joint venture project of similar scope between SVG and Maeda Group is due to start up in early 2008.

All of these projects are integrated with Smar’s Studio application, which is a System302-7 component that allows complete management of a project’s software requirements.

Honeywell in BP Exploration MAC deal

Honeywell has entered into a six-year agreement with BP Exploration to provide main automation contractor (MAC) services at its new and existing facilities with the aim of accelerating production schedules and improving efficiency by integrating all levels of plant operations and automating critical processes.

“Automation will be a key to streamlining operations and improving business performance as we move into the future,” said Tim Bass, BP Exploration’s director of procurement and supply chain management, projects and engineering. “Honeywell has the tools and experience to enable BP to implement its automation strategy, improving integration and the operating efficiency of our assets.”

As the MAC services provider, Honeywell plans to apply an integrated strategy to each design phase, including front-end engineering development, early operator training and process simulation, advanced control modelling, process validation and advanced process control. Honeywell says the integrated approach will result in common interfaces across production and business systems for increased safety and efficiency, higher plant availability, lower operating expenditures and reduced engineering. The integrated MAC approach will allow BP to draw on Honeywell’s process control, MES and safety and security solutions as well as wireless-enabled applications.

Honeywell is to provide the integrated control system for Woodside’s new Pluto liquefied natural gas (LNG) Project in Western Australia. Based on the Pluto gas field north west of Karratha, the project is Western Australia’s first new LNG plant for more than 20 years and will produce 4.3 million tons of LNG per year when it comes on stream in late 2010. It includes sub-sea wells, offshore, unmanned wellhead platform, 180-km trunk line, onshore LNG plant and associated infrastructure. Honeywell’s Experion PKS R300 will control all process operations and provide data from subsystems throughout the facility. Honeywell will also specify, procure, engineer and integrate the emergency shutdown and fire and gas systems. The control system project is scheduled for completion in 2009 and Honeywell’s UniSim Operator Training Simulator will allow process design verification and operator training to begin prior to start-up.

The entire control system will be integrated through Experion with Field Device Manager and Asset Manager helping operators efficiently to monitor and diagnose field devices, and the Uniformance PHD data historian providing efficient and effective data analysis. Honeywell will provide consulting services and applications to assist operators in sorting and prioritizing system alarms.

Field instrument protection specialist Intertec is supplying more than 100 fire protection cabinets to protect instrumentation at the new hydrocracker complex being constructed at the Kirishi oil refinery near St. Petersburg, Russia. The cabinets will provide valve actuators supplied by the field instrumentation vendor for the project, Emerson Process Management, with a minimum of 30 minutes of protection against fire, to ensure that emergency shut-down systems and services can quickly isolate and minimize damage and protect employees, assets and environment. The GRP cabinets are variations of Intertec’s field proven Fire Shelter and, because no Russian or German norms exist for this exact application, their performance was validated before installation by the independent Russian institution, Pozhaudit. Tests on an example cabinet showed that the internal temperature did not rise above 60 °C for at least 30 minutes when subjected to an oil-based fire with a temperature of around 1000 °C.

Metso is to supply a metsoDNA CR automation system to replace the existing controls on the dry stone and asphalt plant at Hanson Aggregates U.K.’s Criggion Quarry in Powys, Wales. Metso’s scope of supply includes its metsoDNA historian, which provides a data warehousing solution for process and product related information. As well as plant management and production reporting, the system will also provide order management functions after start-up in May 2008.